Method of forming a hinge leaf



s. wIPARsoNs METHOD OF FORMING A HINGE LEAF 2 hocks-Sheet 1 Filed July Nov. 20, 1928.

1,692,785 s. w. PARSONS METHOD OF FORMING A HINGE LEAF Filed July 24, 1924 2 Sheets-Sheet 2 55 x Mr.

Patented Nov. 20, 1928.

STUART W. PARSONS, OF NEW BRITAIN,

CONNECTICUT, ASSIGNOR TO THE STANLEY WORKS, OF BRITAIN, CONNECTICUT, A CORPORATION OF CONNECTICUT.

METHOD or FORMING A HINGE LEAF.

Application filed Ju1y24,

This invention relates to hinges and has particular reference to a hinge of that type having two leaves, each with a Single knuckle of generally conical or dome shape, and a pintle, the opposite ends of which are received in said knuckles.

The object of the invention is to provide an improved method by means of which a very strong hinge of this sort and having a pleasing appearance and smooth finish may be manufactured at a relatively low cost.

In the accompanying drawings:

Figure l is a view of a complete hinge and shows one embodiment which the present invention may take;

Fig. 2 is a blank of sheet metal from which one of the leaves is formed, in the present instance the left hand leaf of Fig. l;

Fig. 3 is a view similar to Fig. 2, but showing the knuckle portion of the leaf as being tapered as by a millin operation, a step which may or may not be employed, as desired;

Fig. 4 is a sectional view taken on line 44 of Fig. 3;

Fig. 5 illustrates the outer end of the knuckle portion of the blank turned up slightly preparatory to the rolling operation;

Fig. 6 is a bottom edgeview of what is shown in Fig. 5 and illustrates, in dotted lines, that portion of the blank which is trimmed away; I

Fig. 7 shows the knuckle as having been rolled;

Fig. 8 is a bottom edge view of what is shown in Fig. 7 I

Fi 9 is a view showing the structure of Fig. inverted, and illustrates the. manner in which the leaf is'swaged or upset adjacent the knuckle;

Fig. 10 is a View of the leaf shown in Fig. i

9 and looking in the direction of the arrow 10 of that figure;

Fig. 11. is a side elevational view of the leaf after the first forming operation has been performed on the knuckle Fig. 12 is a view similar to Fig. 11, but with the attaching portion of the leaf trimmed and with the knuckle brought to final shape;

Fig. 13 is a top view of what is shown in Fig. 12;

Fig. 13, is a horizontal section view through the knuckle and shank portion; and

received by mg portion.

1924. Serial No. 727,943.

Fig. 1a shows, more or less diagrammatically and in perspective, a device for rolling the knuckle.

Referring to the drawings in detail, and particularly to Fig. 1, each of the leaves is illustrated as having an attachingportion a; a generally conical dome or shaped knuckle b, and a fiat shank portion cbetween the attaching portion and knuckle. (Z designates the pintle, the opposite ends of which are theknuckles on the respective leaves, and e designates a ball bearing unit about the pintle and between the knuckles. This ball bearing unit may or maynot be used, as desired, and the specific construction of it is not shown, present invention.

In accordance with the present invention,

each of the leaves is formed from a sheet metal blank which is.

above the shank portion 0, and the knuckle has a smooth, unbroken surface whichisdevoid of cracks or crevices.

In carrying out the method of the present invention, each leaf is constructed by first punching from a. flat sheet of metal a blank having a relatively'long attaching or body portion a, a shank laterally from one of attaching portion, portion 5' on said shank portion. knuckle forming portion and, by preference, also the shank portion 0 have their lower edges 10 curved curvature of which will correspond to the apex of the partially formed knuckle shown in Figs. 7 to 10. The upper edge 11 the side edges of the of the knuckle portion preferably extends above-the upper edge of the shank portion, and the outer edge 12 of the knuckle forming portion is inclined to the length of the attachi The upper edge 11 of the knuckle forming portion is devoid of prongs, projections and the like. In the present instance, this edge is-straight, and is inclined upwardly and outwardly from the shank. By

as it forms nopart of the I As hereinafter described in detail, the process of forming eachleaf is so carried out' that the closed end of the knuckle extends and a knuckle forming The I i 1 portion 0, eatendmg on an arc, the center of generally '95 at the juncture of the s of the attaching referencc, but not necessarily, the knuckle forming portion may have, at its outer upper corner, a projection or lug 13 which, when the knuckle forming portion is rolled back upon itself and then pressed to form, engages the upper corner of the knuckle forming por- -ion al'acent the shoulder 14. The next :tep in the operation may be the tapering down of the knuckle forming portion from adjacent its lower edge to its upper edge. This operation may be performed by milling. Figs. 3 and 4 show the knuckle forming portion so tapered. \Vhile this operation is of advantage in that it facilitates the performance of subsequent operations, 'it may be omitted. The outer end of the knuckle forming (portion is then bent upwardly, as indicate in Figs. 5 and 6, and then the outer edge 12 is trimmed away, as indicated by dotted lines 16so that when the knuckle forming portion is completely rolled upon itself. the outer edge of this portion will come flat against that ortion of the blank ank and knuckle.

The knuckle forming ortion is then turned on itself and, in this operation, the metal is rolled preferably on an are so as to bring the knuckle to the tapered form shown in Figs. 7 and 8. Any suitable mechanism may be employed for rolling the knuckle, but, by way of illustration, I have shown, in Fig. 14, one form which this mechanism may take. In this figure, 25 indicates a base having a block 26 provided with a slot or roove 27 for receiving and holding the attac iing portion of the leaf. Pivoted, as by means of a bolt 28 so as to swing in an are generally corresponding to the curvature of the edge 10, is a die 29 having a semi-circular groove 30 in its active face. This groove preferably tapers down in radius towards the pivot of the die 29. When the die 29 is swung to the left, the surface of the groove 30 will turn and roll the knuckle back upon itself and into the she e illustrated in Figs. 7 and 8.

l ke leaf is then upset or bent at the juncture of the shank portion and knuckle so that the axis of the partially formed knuckle is substantially in parallelism with the plane portion and as shown in Figs. 9, 10. The knuckle is then swaged or pressed to final shape in one or more operations. In the present illustrative disclosure, I have shown this as being perormed in two operations; Fig. 11 showing the knuckle after the first operation, and Figs. 12 and 13 showing the knuckle as having been brought to final shape by the second sWa-ging operation. These swaging openitions may be carried out by the knuckle a die having a recess of the same shape and size as the shape and size to be given to the knuckle. Between the first forming orswag'mg operation and theifinal press-v the swaging operation,

- and each of these operations shank portion,

supporting the p knuckle on a die, and bringlng down onto ing or swaging operation, the leaf maybe subjected to an annealing process. During which is carried out while the knuckle is in cold condition, as distinguished from drop forging or electric welding, the metal at the small or upper end of the knuckle is caused to flow and curl in such manner as to completely close this end and provide a single line of juncture extending down from a point adjacent the apex of the knuckle to and along the end of the shank. The metal along this line is closely pressed together but is not joined or united. It will be-secn from the drawings that, during this swaging operation, the knuckle throughout its height is changed from conical shape to dome shape; that is, the finished knuckle is parti-elliptical in longitudinal section. After the external surface of the knuckle has been brought to the final shape shownin Fig. 12, the opening in the knuckle is drilled to the proper diameter so as to closely receive one end of the pintle. The leaf. attaching portion may be cut or trimmed to final shape and size after any of the many operations, but it is here illustrated, by dotted lines, as being trimmed after the first swaging or forming operation of the knuckle.

From the foregoing description taken in connection with the drawings, it will be seen that the leaves of my improved hinge are formed from sheet metal in a very economical and ready manner. The manufacture of the leaves requires but relatively few operations, may be quickly and simply carried out. Since the leaves are formed of sheet metal, they are extremely strong and, therefore, well able to withstand heavy duty. It'is clear, particularly from Figs. 1, 12 and 13, that the knuckles havea smooth, unbroken exterior surface, the metal, where the edges of the knuckle forming portion are brought into engagement, being so merged and pressed together that the joints are practically invisible,

I claim as my invention:

1. The herein described method of forming a hinge leaf having an attaching portion and a dome shaped. knuckle, which consists in stamping. from a sheet of metal a blank having an attaching portion and a knuckle forms ing portion. extending from the side edge of said attaching portion, rolling said knuckle formingportion back upon itself into conical form, upsetting the metal at the juncture of the knuckle to bring the axis of the knuckle substantially in parallelism with the'plane of the attaching portion, and swaging the conically shaped knuckle into dome shape hy forcing the knuckle, in cold condition, into a dome-shaped recess in a die. q M

.2. The herein described method of forming a hinge leaf having an attaching portion and a dome shaped knuckle, which consists in stamping from a sheet of metal a: blank havllh ing an attaching portion and a knuckle forming portion extending from the side edge of said attaching portion, bending up the outer end of said knuckle forming portion, rolling the metal constituting the knuckle on an arc and into conical form, and swaging the partially formed conical knuckle into dome shape.

3. The herein described method of form ing a hinge leaf having an attaching portion and a dome shaped knuckle which consists in stamping from a sheet of metal a blank having an attaching portion, and a knuckle forming portion extending from the side edge of said attaching portion, bending up the outer end of the knuckle forming portion, trimming the outer end of said bent-up portion to provide a. flat surface, rolling the knuckle forming portion back upon itself on an are into conical form, upsetting the metal at the juncture of the knuckle to bring the longitudinal axis of the knuckle substantially in parallelism With the plane of the attaching portion, and swaging the partially formed conical knuckle to dome shape.

4. The herein described method of forming a hinge leaf of the character described, which consists in stamping from a sheet of metal a blank having an attaching portion, a shank extending from one edge of said attaching portion, and a knuckle forming portion extending above the upper edge of said shank and having its outer edge inclined to the length of the attaching portion, said knuckle forming portion having its lower edge on an arc and having at its upper outer corner a projection, rolling the metal of the knuckle forming portion in an are back upon itself into conical form, and then swaging the partially formed conical knuckle to dome shape.

5. The herein described method of forming a hinge leaf of the character described, which consists in stamping from a sheet of metal a blank having an attaching portion, a shank portion extending from one edge of said attaching portion, and a knuckle forming portion on the outer end of the shank, gradually reducing in thickness the knuckle forming portion towards that end which is to form the rounded end of the knuckle, then rolling the metal of the knuckle forming portion in an arc back upon itself into conical form, and then upsetting the metal at the juncture of the shank portion. and knuckle to bring the knuckle with its axis in parallelism to the plane of the attaching portion, and then swaging the partially formed conical knuckle to dome shape.

6. The herein described method of forming a hinge leaf of the character described, Which consists in stamping from a sheet of metal a blank having an attaching portion, a shank portion extending to one side of said attaching portion, and a knuckle forming portion having its outer edge inclined to the length of said attaching portion and having its lower edge curved and longer than its upper edge, said upper edge being devoid of projections and the like; rolling the metal of the knuckle forming portion back upon itself and into conical form, upsetting the metal at the j uncture of said shank and knuckle forming por tion to bring the knuckle With its axis substantially in parallelism to the plane of said attaching portion, and swaging the partially formed conical knuckle into dome shape by forcing the same, in cold condition, into a dome-shaped recess in a die.

7. The method-0f forming a hinge leaf, Which eonsists'in stamping from a sheet of metal a blank having an attaching portion, a shank portion extending from one edge thereof, and a knuckle forming portion at the outer end of said shank portion, tapering said knuckle forming portion; slightly bending theouter edge of said knuckle forming portion, trimming said bent edge, rolling the knuckle forming portion into a conical knuckle, bring the axis of the knuckle substantially parallel to the general direction of the length of the attaching portion, and sWaging said knuckle into dome shape.

8. The method of forming a hinge leaf, Which comprises stain iing from sheet metal a blank having an attaching portion, a shank portion extending from one edge thereof, and a knuckle forming portion at the outer edge of said shank portion, said knuckle forming portion having its outer edge inclined relative to the length of said attaching portion and-having one side edge curved and longer than the opposite side edge,- tapering the shorter edge of said knuckle forming portion, slightly bending the outer edge of said knuckle forming portion, trimming said bent edge, rolling the knuckle forming portion into a conical knuckle, upsetting the metal at the juncture of the knuckle and shank portion to bring the longitudinal axis of the knuckle substantially in parallelism with the plane of the attaching knuckle to dome shape and recess in said knuckle.

STUART W. PARSONS.

drilling a pintle bending the shank portion to portion, sWaging said. 

